Vehicular component assembly with hard coated element

ABSTRACT

A vehicle component assembly includes a hard coated polymeric element with a resinous polymeric molded element or gasket integrally molded to a predetermined area thereof. Preferably, the element is a polycarbonate optical lens, such as a headlight lens, which is coated with a protective coating or hard coat which provides abrasion resistance and optionally includes ultraviolet radiation absorbers to protect the resinous polymeric molded element from UV radiation degradation. Adhesion is improved by priming the area of the polycarbonate element which receives the gasket with a primer coating. Preferably, the area to be gasketed is primed with a first adhesion promoting primer followed by a second adhesion promoting primer, wherein the first adhesion promoting primer improves the adhesion of the second primer to the protective coating, while the second primer, in turn, improves the adhesion of the molded element or gasket to the first primer and the hard coated element. The gasket is preferably molded on a peripheral portion of the element which may include grooves or other formed portions for mechanical interlocking the gasket with the polymeric element. Preferably, the gasket is formed from a melt-processible gasket material, such as polyvinyl chloride, thermoplastic urethane, or an ethylene-styrene polymer.

This is a continuation application of application Ser. No. 09/332,632,filed Jun. 14, 1999, by David E. Nestell and James T. Ainsworth,entitled VEHICULAR COMPONENT ASSEMBLY WITH HARD COATED ELEMENT, which isa continuation application of application Ser. No. 08/895,956, filed onJul. 17, 1997, now U.S. Pat. No. 6,000,814, which are incorporated byreference herein in their entireties.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

This invention relates to vehicle components incorporating polymericelements with members, casings or gaskets formed thereon and, moreparticularly, to vehicle component assemblies including vehicle exteriorlighting assemblies such as a composite headlamp assembly incorporatinga hard coated polycarbonate lens element bonded to a molded polymericgasket.

In recent years, vehicle headlamp assembly designs have been driven bybody styling demands. The lenses of the newer headlamp assemblies aremore contoured so that they follow the contours of the vehicle body.Traditional headlamp assemblies typically included a stainless steelbezel which permitted the lens to be mounted in an opening in thevehicle body. More recently, headlamp assemblies include a preformedgasket which is subsequently attached, for example by an adhesive to theperipheral portion of the lens, which permits the lens to be fitted moreclosely with the body of the vehicle. Such preformed gaskets are,however, difficult to tool and, in some cases, their installation isdifficult and labor intensive. Moreover, conventional lenses are nowtypically molded from a polycarbonate resin. Since polycarbonate lensesare vulnerable to abrasion from road debris and the elements and todiscoloration from ultraviolet radiation, the lenses are coated with ahard coat to provide a durable outer surface which is resistant toscratching and which protects the polycarbonate lens from ultravioletradiation. Heretofore, these hard coatings have inhibited adequateadhesion between the preformed gasket material and the lens.Consequently, in order to improve the adhesion of the gasket to thelens, some conventional gaskets and lenses include structures to providemechanical interlocking of the gasket to the lens to supplement the bondprovided by the adhesive.

Referring to FIGS. 14A and 14B, one conventional, prior knownpolycarbonate lens (100) includes a first slotted groove (102) along itsperipheral edge (104) to provide an anchorage for a conventionalpreformed gasket (106), as will be more fully described below, a secondslotted groove (108) along its peripheral edge for aligning and holdingthe gasket while it is installed on the lens, and a projecting flange(110), which also assists in the alignment and retention of the gasket(106) on the lens during the installation process. As a result, themolding apparatus for the lens requires complicated tooling, and thelenses are subject to tight tolerances.

The preformed gasket (106) includes corresponding structures thatinterlock with the lens grooves and flange. To install the gasket, anadhesive is applied to the gasket or lens perimeter, and a first end(112) of the gasket is seated in the first slotted groove (102) toanchor one end of the gasket (106) while the gasket is stretched aroundthe perimeter of the lens. As the gasket is stretched around theperimeter, an intermediate portion of the gasket is then seated in thesecond slotted groove (108) to align the gasket and provide furthermechanical interlocking of the gasket to the lens. Then the second ofend (114) of the gasket is wrapped around the perimeter of the lens andseated in the first slotted groove (102) adjacent the first end of thegasket such that the gasket ends define a break or space 115 (FIG. 14A).In this manner, these grooves and flange of the lens and correspondingstructures on the gasket cooperate to align the gasket and tomechanically retain the gasket on the lens while the adhesive cures andprovide mechanical interlocking of the gasket to the lens. Such processis often difficult and time consuming. Also, the retention of the gasketon the lens is sometimes less than adequate, as is the adhesion betweenthe gasket and lens. While these gaskets have improved the fit-up of theheadlamp assembly with the contoured vehicle body, the apparatus used toform these gaskets is also difficult and expensive to tool.

Further, gaskets (106) may be formed with retainers or tabs (116). Theretainers (116) project from the gasket and secure to a housing byfasteners to provide a means for temporarily securing the lens and thegasket to the housing during installation. These retainers furthercomplicate the molding process of the gasket. In some applications, thegasket is molded from two materials, with the second material formingthe retainers having a greater durometer hardness to increase thestiffness of the gasket where the retainers project from the gasket.Again, this process increases the cost of the gasket and is alsodifficult to tool.

Despite the improved fit up, these preformed gaskets may not provide thedesired life expectancy and may require reinstallation or replacement.Furthermore, because of the geometry of the gasket, there may also be agap between the first and second ends of the gasket such as that shownat 115 in FIG. 14A. This gap may affect the aerodynamics of the vehiclebody or the wind noise of the assembly. Moreover, installation of thesepreformed gaskets is labor intensive, requiring manual manipulation ofthe gasket around the lens. This manual manipulation may lead to workerfatigue and, ultimately, may increase the number of defectiveinstallations and the cost of the vehicle.

Consequently, there is a need for vehicle component assemblies whichincorporate resinous elements, especially hard coated polycarbonatelenses of vehicle headlamp assemblies, and cooperating gaskets or moldedmembers which will exhibit improved adhesion between the gasket ormolded member and the resinous element. Moreover, there is a need forsuch assemblies which can be manufactured and installed withsignificantly reduced labor, time, and costs.

SUMMARY OF THE INVENTION

Accordingly, the present invention provides a vehicle component assemblysuch as a modular headlamp assembly which is ready for installationvirtually entirely from the exterior of a vehicle or other supportingbody in a manner which is heretofore been unknown. The headlamp assemblycombines an optical element, typically formed of a polymeric material,such as a polycarbonate material, which has been shaped and coated witha protective coating to be ready for application in a headlamp assemblyof a vehicle, and a flexible, resilient gasket which is integrallymolded onto the perimeter of the optical element to provide a cover forthe gap between the optical element and the opening of the vehicle body.The invention therefore eliminates the need for piecemeal assembly ofthe optical element and gasket of the headlamp assembly, while alsoproviding a secure bond of the gasket material to the hard coatedpolycarbonate optical element to form a lens module, all in a moldingprocess in a manner heretofore unknown.

According to one aspect of the invention, an optical component of avehicle comprises an optical element having a peripheral portion and agasket. The peripheral portion includes inner and outer peripheral sidesurfaces and a peripheral edge surface. The optical element includes aprotective coating on at least one of the inner peripheral side surface,the outer peripheral side surface, and the peripheral edge surface, anda primer coating over at least a portion of the protective coating. Thegasket is integrally molded on at least a portion of the primed portionon at least one of the inner peripheral side surface, the outerperipheral side surface, and the peripheral edge surface of the opticalelement. The gasket is thus bonded to at least a portion of the primedarea of the optical element and includes extending portions at positionsspaced from the optical element adapted to cover a gap between theoptical element and the vehicle body.

In one form, the optical element comprises a polymeric optical element,such as a polycarbonate optical element. Furthermore, the opticalelement may comprise a lens, such as a headlamp lens. Preferably, theheadlamp lens has a contoured surface wherein the contoured surfacefollows the contour of the body of the vehicle. The peripheral portionof the lens may include at least one cooperating structure, for examplea groove which extends around at least a portion of the lens, athrough-hole, or a lip, which provides mechanical interlocking of thegasket and the lens. In other aspects, a conventional lens element maybe used, which typically includes one or more grooves extending into theperipheral edge surface of the lens.

In another form, the gasket material may comprise a melt-processiblegasket material or a non melt-processible gasket material. For example,as suitable melt-processible material includes polyvinyl chloride,styrene/butadiene/styrene (SBS) elastomers,styrene/ethylene/butadiene/styrene (SEBS) elastomers, copolyesterelastomers, polyether blockamides, and thermoplastic urethane. Othersuitable melt-processible gasket materials include cross-linkedmaterials, for example styrene butadiene rubber (SBR) elastomer,ethylene propylene diene terpolymer (EPDM) elastomer, and ethylenepropylene copolymer (EPM) elastomer. Suitable non melt-processiblegasket materials include thermosetting reaction injection moldedurethanes. Preferably, the gasket material has a hardness in a range ofabout 40 to 100 Shore A durometer. More preferably, the gasket materialhas a hardness in a range of about 55 to 100 Shore A durometer. Mostpreferably, the gasket material has a hardness in a range of about 65 to85 Shore A durometer.

In yet further aspects, the protective coating comprises an organic hardcoat, such as silicone, an inorganic hard coat, such as transition metalcompounds, or an organic/inorganic hybrid hard coat, such as organicmodified inorganics, for example a silicone modified silicon dioxide,which is applied to at least the outer, exposed surface of the opticalelement and protects the optical element from abrasion. Suitableinorganic hard coats include, for example, metal oxides, and metalnitrides. For example, metal oxides, such as silicon dioxide, may beused.

In another form, the optical component preferably includes ultravioletradiation absorbers to protect the polycarbonate material from radiationdamage, which are incorporated into the optical element and/or theprotective coating. The ultraviolet radiation absorbers may beincorporated into an intermediate primer coating, which is applied tothe optical element to improve the adhesion between the hard coating andthe optical element.

According to another aspect of the invention, a vehicle lightingassembly includes a housing adapted for mounting in the body of avehicle and a lens module mounted to the housing. The lens moduleincludes a lens and a protective coating on at least an exterior surfaceof said lens, and a primer coating over at least a portion theprotective coating. The lens module further includes a gasket integrallymolded on at least a portion of the primed area and is adapted to covera gap between the lens and the body of the vehicle. The gasket materialpreferably comprises either a melt-processible gasket material or a nonmelt-processible gasket material.

In one form, the lens module is secured to the housing, for example byultrasonic welding or mechanical attachment, to provide a water tightseal between the lens module and the housing, which eliminates the needfor forming or providing retainers on the gasket.

According to a further aspect, a vehicle component assembly includes apolymeric body having a protective coating thereon and at least oneprimer coating overlaying at least a portion of the protective coating.A member is integrally molded onto at least a portion of the primercoating, with the molded member extending away from the polymeric bodyadapted to extend between the body and the vehicle.

According to yet another aspect, a method of attaching a molded memberto a polymeric vehicle element includes providing a polymeric vehicleelement, applying a primer to a predetermined area of the element, andforming an integrally molded member on at least a portion of thepredetermined area from a polymeric material. The vehicle elementincludes a protective coating to protect the vehicle element fromabrasion and, preferably, ultraviolet absorbers to protect the vehicleelement from ultraviolet radiation degradation.

In one aspect, the molded member is formed by injection molding a gasketmaterial onto the vehicle element. Injection molding may includereaction injection molding the member onto the vehicle element.Preferably, the primer is applied to a peripheral portion of the vehicleelement to improve the adhesion between the molded member and thevehicle element. More preferably, the vehicle element is primed with afirst primer and then the first primer is primed with a second primer.The first primer is provided to increase the adhesion between theprotective coated vehicle element and the second primer which, in turn,is adhered to the molded member.

In other aspects, the method further includes preheating the vehicleelement, for example by applying warm air to the vehicle element. Bypreheating the vehicle element, the time for the primer or primers toflash is reduced, and the moldability of the part is improved.

The vehicle components and/or lighting assemblies of the presentinvention overcome the differences of curvature and dimensions betweenthe vehicle element and the body panels of a vehicle by providing aresilient gasket or member formed on the element preferably by molding.The vehicle is preferably a polycarbonate element with a protectivecoating and protect the element from abrasion and, preferably, includesultraviolet radiation absorbers to protect the element from ultravioletradiation damage. The primer coating increases the adhesion between themolded gasket or member and the protective coated element in a mannerthat provides superior adhesion characteristics heretofore unknown.Moreover, by molding the gasket or member onto the vehicle element, theassembly and installation time is significantly reduced thereby savingcosts.

These and other object, advantages, purposes and features of theinvention will become more apparent from the study of the foregoingdescription taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a first embodiment of the presentinvention comprising a headlamp assembly installed in a vehicle;

FIG. 2 is a front elevational view of the headlamp assembly of FIG. 2;

FIG. 3 is a top plan view of the headlamp assembly;

FIG. 4 is a rear elevational view of the headlamp lens assembly;

FIG. 5 is a rear elevational view of the protective coated polymericlens of the present invention before formation of the molded memberthereon;

FIG. 6 is a perspective view of the headlamp assembly;

FIG. 7 is a cross-sectional view taken along line VII—VII of FIG. 1;

FIG. 8 is an enlarged cross-sectional view taken along line VIII—VIII ofFIG. 1;

FIG. 9 is an enlarged cross-sectional view taken along line IX—IX ofFIG. FIG. 1;

FIG. 10 is a cross-sectional view taken along line X—X of FIG. 3;

FIG. 11 is a cross-sectional view taken along line XI—XI of FIG. 5;

FIG. 12 is a cross-sectional view of a second embodiment of the presentinvention comprising a decorative panel assembly;

FIG. 13 is a cross-sectional view of a mold assembly used in forming themolded member about the periphery of the lens of the first embodimentheadlamp lens assembly of the present invention;

FIG. 14A is a rear elevational view of a conventional prior known,headlight lens assembly with a preformed gasket manually installedaround the lens perimeter; and

FIG. 14B is a rear elevational view of a conventional prior known,headlight lens with the gasket removed.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in greater detail, FIG. 1 illustrates oneform of a vehicle component assembly incorporating the presentinvention. One preferred form of this invention is a headlamp assembly10 installed in the body of a vehicle 12. The headlamp assembly mayinclude a lens module formed from a polymeric lens, for example apolycarbonate lens, which is coated with a transparent protectivecoating such as a silicone or ceramic hard coat but which also includesa molded polymeric member, which forms a gasket on the peripheral edgeof the lens and is bonded securely and uniformly thereto in a heretoforeunknown manner. As will be explained below, the present invention isuseful for forming a wide range of vehicle component assemblies,especially where a gasket or other formed member must be securelyattached to a protective coated polymeric element to form a completeassembly.

As shown in FIGS. 2-4, headlamp assembly 10 of the preferred embodimenthas a peripheral outline or configuration design to match the contour ofthe body of vehicle 12. Headlamp assembly 10 is positioned in a recessedopening 14 between a fender 16, a bumper cover 18, and a hood 20 of thevehicle body. Headlamp assembly 10 includes a cylindrical housing 22(FIGS. 6 and 7) and a lens module 23 formed from a contoured lens 24which is mounted to a forward open end 22 a of cylindrical housing 22 bywelds 26 formed by ultrasonic welding (FIG. 7), as will be more fullydescribed below. Housing 22 is preferably molded from a resinous plasticmaterial such as polyvinyl chloride (PVC), and is mounted in the vehiclebehind bumper cover 18 and adjacent fender 16 using conventional clipsor projecting bosses 25 a and fasteners 25 b, so that lens 24 is alignedin opening 14 and is substantially flush with and follows the contour ofthe body of vehicle 12. The lamp (not shown) of the headlamp assembly ishoused and supported in cylindrical housing 22 and is electricallycoupled to the vehicle battery by wiring that is directed into thehousing through a flexible conduit 25 c, such as a rubber hose, thatconnects to a port (not shown) on the housing.

Lens 24 is a polymeric lens preferably molded from a plastic resin, suchas polycarbonate. More preferably, lens 24 comprises a GE LEXAN™polycarbonate lens, available from General Electric Plastics. To protectlens 24 from deterioration from the elements, including rain, snow, ice,heat, and from abrasion damage from sand, dirt, cleaning cloths ordevices, and the like, lens 24 is coated with a protective outer layer27 a (FIG. 9). Layer 27 a may comprise an organic hard coat, aninorganic hard coat, or an organic/inorganic compound. Examples oforganic hard coats include a silicone hard coat, such as AS4000available from GE Silicones of Waterford, N.Y. or from Mitsubishi.Examples of an inorganic hard coat include transition metal compounds,for example a titanium or silicon dioxide.

To protect lens 24 from UV radiation degradation, lens module 23preferably includes ultraviolet absorbers or stabilizers. For example,these ultraviolet radiation absorbers or stabilizers may be incorporatedinto an intermediate primer coating 27 d, which is typically applied tolens 24 by the manufacturer to improve the adhesion between theprotective hard coat 27 a and lens 24. Intermediate primer coating 27 dpreferably comprises an acrylic based primer with optional UV absorbersor stabilizers incorporated therein, which reduce the UW lighttransmission. Alternatively, UV absorbers may be incorporated into theprotective outer layer 27 a, which may include a monomer compositionthat includes the UW absorbers. In addition or alternatively, lensmodule 23 may include such UW absorbers in the material forming lens 24.It can be appreciated from the foregoing that lens 24 may be protectedfrom ultraviolet radiation damage either by incorporating UW absorbersinto the material of the lens, in intermediate primer coating 27 d,and/or in protective hard coating 27 a. Such ultraviolet stabilizingagents should be substantially transparent in the visible regions andfunction to absorb ultraviolet radiation, quench degradation freeradical reaction formation, and prevent degradative oxidative reactions.

Although many materials known to absorb ultraviolet radiation may beemployed herein, preferred ultraviolet stabilizing agents include“UINUL” 400[2, 4-dihydroxy-benzophenone (manufactured by BASF Corp.,Wyandotte, Michigan)], “UVINUL” D 49[2, 2′-dihydroxy-4,4′-dimethoxybenzophenone (BASF Corp.)], “VINUL” N 35[ethyl-2-cyano-3,3′-diphenylacrylate (BASF Corp.)], “UVINUL” N539[2-ethylhexyl-2-cyano-3, 3′-diphenylacrylate (BASF Corp.)], “UINUL” M40[2-hydroxy-4-methoxybenzophenone (BASF Corp.)], “UVINUJL” M408[2-hydroxy-4-octoxybenzophenone (BASF Corp.)], “TIULIN” P [2-(2′hydroxy-5′-methylphenyl)-triazole] (Ciba Geigy Corp.)], “TINUVIN”327[2- (3′, 5′-di-t-butyl-2′-hydroxyphenyl) -5-chloro-benzotriazole(Ciba Geigy Corp.)], “TINUVIN” 328[2- (3′,5′-di-n-pentyl-2′-hydroxyphenyl) -benzotriazole (Ciba Geigy Corp.)] and“CYASORB UV” 24 [2, 2′dihydroxy-4-methoxy-benzophenone (manufactured byAmerican Cyanamid Co., Wayne, N.J.)], with “UVINUTL” M 40, “UVINUL” M408, “UINUL” N 35 and “UVINUL” N 539 being the most preferredultraviolet absorbing/stabilizing agents when used in a by-weight rangeof about 0.1% to about 15%, with about 4% to about 10% being preferred.

Ultraviolet radiation absorbing monomers may also be advantageouslyemployed herein. Preferred among such monomers are 1, 3-bis-(4-benzoyl-3-hydroxyphenoxy) -2-propylacrylate,2-hydroxy-4-acryloxyethoxybenzophenone, 2-hydroxy-4-octoxybenzophenoneand 4-methacryloxy-2-hydroxybenzophenone, as they perform the dualfunction of acting as a monomer component, or a portion thereof, and asan ultraviolet absorbing/stabilizing agent.

Further, ultraviolet absorbing layers may be coated onto, or adhered to,lens 24 to assist in shielding the lens from the degradative effect ofultraviolet radiation. Suitable ultraviolet absorbing layers includethose recited in U.S. Pat. No. 5,073,012 entitled “Anti-Scatter,Ultraviolet Protected, Anti-Misting Electro-Optical Assemblies”, filedMar. 20, 1990, or as disclosed in co-pending U.S. patent applicationSer. No. 08/547,578 filed Oct. 24, 1995, the disclosures of which arehereby incorporated by reference herein.

Examples of such ultraviolet absorbing layers include a layer of DuPontBE1028D which is a polyvinylbutyral/polyester composite available fromE. I. DuPont de Nemours and Company, Wilmington, Del., and SORBALITE™polymeric UV blockers (available from Monsanto Company, St. Louis, Mo.)which comprise a clear thin polymer film, with UV absorbing chromophoresincorporated, such as by covalent bonding, in a polymer backbone. TheSORBALITE™ clear thin polymer film when placed on a surface of the lensto the source of UV radiation (such as the sun), efficiently absorbs UVlight below about 370 nm with minimal effect on the visible region.Thickness of the SORBALITE™ film is desirably in the range of about 0.1microns to 1,000 microns (or thicker); preferably less than 100 microns;more preferably less than about 25 microns, and most preferably lessthan about 10 microns. Also, UV absorbing thin films or additives suchas cerium oxide, iron oxide, nickel oxide and titanium oxide or suchoxides with dopants can be used to protect lens 24 from UV degradation.Further, as described above, UV absorbing chromophores can beincorporated, such as by covalent bonding, into intermediate layer 27 d,lens 24 or into protective coating 27 a to impart enhanced resilience toUV radiation. Also, near-infrared radiation absorbing species may beincorporated into lens 24, protective coating 27 a, or intermediatelayer 27 d.

As best seen in FIGS. 2-5, lens module 23 includes an integrally moldedmember defining a gasket 28, which extends around the perimeter of lens24 and projects outwardly from a peripheral edge 30 of lens 24 to coverthe gap between lens 24 and fender 16, bumper cover 18, and hood 20 ofvehicle 12. Notably, lens module 23 may comprise a pre-coated,pre-formed lens in which protective coating 27 a has been applied usingconventional techniques by the manufacturer. For example, protectivecoating 27 a may be applied using in-molding techniques, chemical vapordeposition (CVD) techniques, for example low pressure or plasma enhancedCVD vacuum deposition techniques, such as evaporation or sputtering, orfilm transfer techniques, or the like. Alternatively, lens module 23 maycomprise a pre-formed, uncoated lens, which optionally is receivedpre-formed and uncoated at the lens module assembly site, and which isthen subsequently coated at the lens module assembly site withprotective layer 27 a using any one of the above mentioned techniques.For example, organic or inorganic protective coatings may be applied tothe uncoated pre-formed lens using dip coating, spray coating, meniscuscoating, spin coating, and flow coating. The inorganic protectivecoating may be additionally applied using vacuum deposition, evaporationdepositing, sputtering depositing, or chemical vapor deposition, such asatmospheric or plasma assisted chemical vapor deposition, ion depositiontechniques, or pyrolysis. Alternatively, the inorganic protectivecoating may be applied by a film transfer process. The protectivecoating is preferably cured thermally or by radiation UV energy.

Moreover, lens module 23 may be formed by a unitary molding operation inwhich lens 24 is molded from resin molded material and with theprotective coating and any intermediate primer coatings being in-moldapplied in the same mold, such as by use of transfer film, in-moldcoating, a co-injection process, or the like. As these molding methodsare conventionally known in the molding art, reference is made theretowithout further description of the processes involved. Optionally, themolded member can be co-injected in a unitary molding process or may bemolded in an adjacent operation immediately subsequently following thelens molding process. Whether lens 23 comprises a pre-formed, pre-coatedlens, a pre-formed, uncoated lens, or a lens formed in a mold with theprotective coating or coatings and gasket formed in the same mold, thefinal product comprises a lens module with an integrally formed moldedmember.

Gasket 28 may engage or flex and resiliently engage any one or more offender 16, bumper cover 18, and hood 20 to enhance the aerodynamics ofthat portion of the vehicle body, e.g. hood 20 as in FIG. 9. Gasket 28is preferably a melt processible material, such as a thermoplasticresinous material, for example polyvinyl chloride (PVC), or a blockcopolymer such as a styrene/butadiene/styrene (SBS) elastomer, astyrene/ethylene/butadiene/styrene (SEBS) elastomer, a copolyesterelastomer, a polyether block amide, and a thermoplastic urethane.Suitable melt-processible materials also include physical blends andalloys such as polypropylene and EPDM, polyvinylendene chloride andethylene vinyl acetate, thermoplastic olefins and EPDM, and PVC andnitrile rubber. Another class of suitable melt-processible materialsincludes multi-phase graft copolymers such asmethacrylate/butadiene/styrene (MBS). Also, blends of the above polymersamong themselves or with another polymer can also be a suitablematerial.

Some examples of block copolymers are KRATON™ D (which is SBS) andKRATON™ G (which is SEBS), both available from Shell Chemical Company,Troy, Mich.; HYTRELTM™ (a copolyester elastomer), available from DuPontChemical, Wilmington, Del.; PEBAX™ (a polyether block amide), availablefrom Elf Atochem North America Incorporated, Philadelphia, Pa.;ELASTOLLANM (a thermoplastic urethane), available from BASF, Wyandotte,Mich.; and PELLETHANET (a thermoplastic urethane), available from DowChemical Company, Midland, Mich.

Examples of physical blends and alloys include SANTOPRENE™ (a blend ofpolypropylene and EPDM), available from Advanced Elastomers, AuburnHills, Mich.; ALCRYN™ (a blend of polyvinyledene chloride and ethylenevinyl acetate), available from DuPont Chemical, Wilmington, Del.;CHEMIGUM™ (a blend of PVC and nitrile rubber), available from GoodyearTire and Rubber Company, Akron, Ohio; VINYPRENE™ (a blend of PVC andethylene terpolymer), available from Vista Chemical Company, Houston,Tex.; 93-X 0401 A-80 (a blend of polypropylene and EPDM), available fromTeknor Apex Company, Pawtucket, R.I.; and SARLINK™ 3000 (a blend ofpolypropylene and EPDM), available from DSM Thermoplastic ElastomersIncorporated, Leominster, Mass.

Alternatively, it may be desirable to use melt-processible materialsthat are crosslinkable such as by vulcanization. Examples ofmelt-processible gasketing material with a crosslinked structure formedfrom formulations with unsaturation in the polymer backbone are styrenebutadiene rubber (SBR) elastomer and ethylene propylene diene terpolymer(EPDM) elastomer. Cross-linking between sites of unsaturation onadjacent polymer chains is achieved preferably via sulfur vulcanizationas is commonly known. An example of a gasketing material formed from aformulation that is a peroxide cross-linkable system is ethylenepropylene copolymer (EPM) elastomer. It should be those skilled in theart that where the molded member is formed from material requiringrelatively high mold temperatures, for example EPDM, the material oflens 24, therefore, must be suitable and have sufficient heat deflectiontemperatures to withstand these higher processing temperatures.

Also, gasket 28 can be formed of melt-processible low-halogen orhalogen-free polymer resin material such as resins based on polyolefinsproduced using metallocene catalysis. For example, ethylene-styreneinterpolymers (ESI) can be used that are available from Dow Chemical,Freeport, Tex., and that, preferably, utilize Dow's INSITE™single-catalyst technology wherein, depending on the amount of styreneincorporated, the solid state of the polymer can exhibit a variety ofstructures, including semicrystalline and amorphous rubber.

Alternatively, polyolefin based resins available from TOSOH Company ofTokyo, Japan and formed using TOSOH's CATALLOCENE™ metallocene catalyststechnology can be used to form gasket 28.

Other suitable gasketing materials which are not melt-processible, arethermoset materials, such as those materials used in liquid injectionmolding processes, i.e., RIM urethanes.

Furthermore, gasket 28 is preferably molded from gasketing materialhaving a hardness of about 40 to 100 Shore A durometer. More preferably,gasket 28 is molded from gasket material having a hardness of about 55to 100 Shore A durometer. Most preferably, the gasketing material has ahardness of about 65 to 85 Shore A durometer.

Gasket 28 is integrally molded onto the peripheral edge 30 of lens 24 bya molding apparatus 58 (FIG. 13). As best seen in FIGS. 6-11, peripheralportion 30 of lens 24 includes an outer peripheral side surface 31, aninner peripheral side surface 32, and a peripheral edge surface 33.Preferably, protective layer or coating 27 a is provided on at least theouter surface of lens 24 and extends over outer peripheral side surface31. In the illustrated embodiment, protective coating 27 a extends overboth the outer surface and the inner surface of lens 24. But it shouldbe understood that it may be more typical to provide protective coating27 a only on the exposed outer surface of lens 24. Furthermore, asdescribed previously, lens module 23 may include intermediate primercoating 27 d applied to lens 24 to promote the adhesion of protectivecoating 27 a to lens 24. Outer peripheral side surface 31, innerperipheral side surface 32, and peripheral edge surface 33 each includea substantially planar or smooth molding surface 31 a, 32 a, and 33 a,respectively, (FIG. 11) onto which the gasket material forming gasket 28is molded, as will be fully described below. It should be understoodthat lens module 24 may be formed using a conventional lens element,such as lens 100 shown in FIG. 14A, may also be molded with gasket 28.

Furthermore, lens 24 may be formed or provided with one or morethrough-holes or other cooperating structures, for example grooves orchannels, which are located in the region or area to be molded withmolded member 28. The cooperating structures may be spaced or extendaround at least a portion of the periphery of lens 24. The gasketmaterial forming the molded member flows into these cooperatingstructures and thereby forms mechanical interlocking or bonding ofgasket 28 to lens 24 to further enhance the integral bond between gasket28 and lens 24. Referring to FIGS. 7-11, in the illustrated embodiment,lens 24 includes longitudinally extending ridges or grooves formed oninner and outer peripheral side surfaces 31 and 32 of portions ofperipheral edge 30, with molding surfaces 31 a and 32 a defined by thebottom wall of the respective grooves. In this manner, the grooves formprojecting lips 30 a over at least a portion of peripheral edge 30 toprovide mechanical bonding or interlocking of gasket 28 to lens 24.

As best seen in FIGS. 6-10, gasket 28 may be molded onto all threesurfaces 31, 32, and 33 to provide a continuous seal and superioradhesion characteristics to the lens 24. However, it should beunderstood that gasket 28 may be molded on a single surface, for exampleinner peripheral side surface 32. In this manner, lens module 23 may bepositioned flush with the outer surface and contour of the vehicle bodyand appear to be free floating in the recessed opening of the vehicle.Such a flush mounted application is particularly suitable for vehicleswhere the gap or spacing between the lens and the body of the vehicle isminimal. It should be also be understood that gasket 28 may be injectionmolded onto two sides of the lens 24, for example, the inner peripheralside surface and the peripheral edge surface of lens 24. In such case,the headlamp assembly can be positioned to achieve a flush mounting ofthe lens with respect to the body of the vehicle.

Referring to FIGS. 3-6, lens 24 includes an outer convex surface 34 andan inner concave surface 36. Outer concave surface 34 includes atransparent, light transmitting region 38 which is bounded on one sideby a crescent shaped, non-transparent region 40. The inner surface oflight transmitting region 38 includes a projecting flange 42 whichextends around the perimeter of light transmitting region 38 and extendsinto housing 22. As best seen in FIGS. 7 and 10, flange 42 includes abase portion 42 a and a projecting lip portion 42 b. Forward open end 22a of housing 22 includes an annular groove or recess 43 into whichprojecting lip portion 42 b of flange 42 extends. Flange 42 ispreferably rigidly secured to forward end 22 a of cylindrical housing22, for example, by welding or an adhesive. Most preferably, flange 42is secured to housing 22, preferably by heat staking, ultrasonicwelding, or mechanical fastening, to form a fluid tight connectionbetween lens module 23 and housing 22.

An inner surface 40 a of non-transparent region 40 includes sharplydefined, parallel optical lines 44 formed between parallel ridges orpeaks 45 b and valleys 45 a. Inner surface 40 a is coated with areflective material 46, such as nickel chrome, or aluminum paint, toform a reflective area 47 which reflects light incident thereon from theouter, convex side 34 of the lens. In this manner, lens 24 also providesa reflective element so that when light from an on-coming car isdirected onto reflective area 47, the driver of the on-coming vehiclewill have a better view of vehicle 12 when the on-coming car approachesvehicle 12 from the side. In addition, lens 24 may include a second,crescent shaped shaded area 48 (FIGS. 2-5) formed by small, thin linesor ridges molded on the interior surface of the lens. Such lines orridges form a fresnel lens area which diffuses the light transmittedfrom the headlamp. Reflective area 47, light transmitting area 38, andfresnel lens area 48 are bounded by peripheral edge 30.

Gasket 28 also includes a peripheral flange 52 which may have a varyinglateral extent or dimension and thickness to accommodate different bodystyles and arrangements. Referring to FIGS. 2 and 6-8, flange 52 definesa thin, resilient, flexible lip 53, which may engage at least a portionof the perimeter of opening 14. As shown in FIGS. 7 and 8, the free endof lip 53 engages a recess or groove 34 in bumper cover 18 to seal outwater, dirt and the like. In the illustrated embodiment, lip 53 may alsoextend a sufficient lateral distance away from lens edge 30 at aposition spaced from the area where lip 53 engages bumper cover 18 toengage the underside of hood cover 20 (FIGS. 7 and 9). It should beunderstood, however, that the thickness and lateral dimension of lip 53may vary according to the type and model of vehicle 12 and is generallyprovided to cover the gap between lens module 23 and the body of thevehicle.

The method of forming assembly 10 preferably begins with the cleaning ofthe surface of lens 24 to receive the gasket material by wiping with asuitable solvent, such as isopropyl alcohol, which removes oils or otherdirt and debris. The alcohol mobilizes any contaminants and evaporatesin a short period of time leaving substantially no residue to interfereor degrade the process. Following the cleaning of lens 24, and aftersufficient time has lapsed to evaporate any remaining solvent, a coating27 b of a primer adhesive is applied to that portion or area of theprotective coated lens which will receive molded gasket 28 (FIG. 9). Itis preferred that the application of the primer adhesive be constrainedto the peripheral edge of lens 24. The primer coating 27 b improvesadhesion of the gasket material to the protective coated lens.Preferably, the primer is applied to the surface of the lens prior toreceiving gasket 28.

One example of such a primer has an acrylic base including an epoxycomponent, and may further include an adhesion-promoting agent such as asilane coupling agent, a titanium coupling agent, or a zirconiumcoupling agent. More preferably, where lens 24 comprises a protectivecoated polycarbonate lens, the area to be encapsulated with the gasketmaterial is treated with a urethane glass primer before molding, such asEssex 43520A available from Essex Specialty Products, of Auburn Hills,Mich., or a solvent based acrylic primer, for example AS1100 vailablefrom Union Carbide or OSI.

In one embodiment, the primer adhesive is applied by a sprayer, wiper,roller, extruder, or other technique to the preferred thickness. Sinceit is anticipated that use of this invention will typically involveproduction of a large number of lenses, an automated application may beused. Preferably, the primer coating is applied to the area to beencapsulated using an applicator, such as a foam brush. The primer isallowed to flash completely over a period of time which, for the Essexprimer, is up to about 15 minutes.

To further improve the adhesion between the gasket material and thecoated polymeric lens, a second primer coating 27 c may be applied ontothe area previously coated with the first primer layer 27 b The secondprimer coating 27 c preferably comprises a water based urethane glassprimer, such as DX-4, which is available from Donnelly Corporation ofHolland, Mich., and is applied using an applicator such as a foam brush.The first primer improves the adhesion between the protective coatedpolymeric lens and the second primer, and the second primer improves theadhesion between the gasket and the first primer. Similarly, the secondprimer is allowed to flash completely over a period of time. For theDonnelly primer, such period is up to about 60 minutes. It should beunderstood that the primers described herein, namely the Essex and theDonnelly primers, have been found particularly suitable when molding aPVC member, such as a gasket, onto a polycarbonate element that has beencoated with either the GE AS4000, Mitsubishi, or Bayer protectivecoatings. Other primers may also be used depending on the particularprotective coating and on the desired gasket material.

Subsequent to the application of the primer adhesive coatings, the lenssubstrate may optionally be preheated to a temperature no greater than160° F., and more preferably to a temperature between 100° F. and 160°F. Most preferably, lens 24 may be preheated to a temperature of about130° F. By heating lens 24, the primer coatings flash at a faster rate.Preheating the primed lens may be accomplished by infrared heating and,preferably, by directing warm air onto the primed lens. It has beenfound that by heating the lens and the adhesive primer to a temperatureless than 160° F. and maintaining that temperature up through the timethe gasket is formed on the lens, an exceptionally strong bond and waterresistant barrier is formed between the lens and the gasket. The minimumtemperature for a primer adhesive at which such a bond occurs is knownas the “primer transition temperature.” The primer transitiontemperature may also be defined as that temperature for a given primerwhere the adhesive quality significantly changes and improves.Alternatively, the primed, protective coated lens may be plasmaactivated before molding.

The primed, protective coated polymeric lens and any attachments arethen loaded into molding apparatus 58. Preferably, lens module 23 isformed by integrally molding lens 24 with gasket 28 in a clear andessentially dust free environment. The gasket material is molded ontolens 24 preferably by injection molding. Furthermore, gasket 28 used inaccordance with this invention, as described above, is preferably madefrom a melt-processible material which requires the application of heatto mobilize or melt the material. Heat is required to process themelt-processible material under conventional molding techniques such asinjection molding, extrusion, blow molding, compression molding, andsimilar techniques. The application of heat during molding furtherimproves the adhesion between the gasket 28 and the hard coated lens.Moreover, heat may be applied to the molded, hard coated lens after themolding process is complete, which may further increase the adhesion ofgasket 28 to the hard coated lens. Therefore, lens 24 may be heatedbefore, during, and/or after the molding process to increase theadhesion between gasket 28 and lens 24.

Although the present invention has been described in reference tomolding the perimeter or peripheral portion of a polymeric element, itshould be understood that molding may be carried out on intermediateportions of a polymeric element using this process. For example,referring to FIG. 12, a decorative trim assembly 10′ may include a panel12′ with a fastener or attachment 14′ adhered to an inner side 16′ ofpanel 12′ for securing panel 12′ to the body 15′ of a vehicle. Fastener14′ may be adhesively bonded to inner side 16′ by a suitable adhesiveand then a spacing or sealing member 18′ may be molded there around.Alternatively, fastener 14′ may be encapsulated by molded member 18′thus eliminating the need for an adhesive between panel 12′ and fastener14′. In order to obscure the view of the fastener 14′ and molded member18′, panel 12′ may include an opaque coating or frit coating on theinner side 16′ of panel 12′. In a similar manner to the previousembodiment, a modular panel 13′ is formed by molding member 18′ on panel12′. Panel 12′ comprises a polymeric panel with a protective coating 16a′ and an optional intermediate primer coating 16 d′ similar to thatdescribed in the previous embodiment. In the same manner, the area onwhich molded member 18′ is to be molded is primed with at least oneadhesive promoting primer coating 16 b′ and, preferably, with a secondprimer coating 16 c′. Reference is made to the earlier embodiment 10 forexamples of the protective coating, intermediate primer coating,ultraviolet radiation absorbers/stabilizers, suitable adhesion promotingprimers, and suitable gasket or seal materials. It should be understoodthat various other vehicle components, such as trim assembly 10′, mayinclude gaskets or moldings formed thereon at various positions withoutthe necessity of fasteners such as that at 14′ bonded to the panel orsubstrate prior to forming the molded member.

As best seen in FIG. 13, molding apparatus 58 comprises an injectionmold with a single cavity. It should be understood that a multiplecavity mold may also be used. Furthermore, molding apparatus maycomprise a co-injection molding apparatus so that lens module 23 may beformed by in-molding, in which all or some of the components areinjected to form either an intermediate product, such as a coated lens,or the final product, a lens module formed from a protective coated lenswith an integrally molded member.

In the illustrated embodiment, molding apparatus 58 comprises a singlemold apparatus and includes upper and lower plates 60 and 62,respectively each defining upper and lower parting lines 63 and 64,respectively. Plates 60 and 62 are respectively configured to hold lens24 therebetween when clamped together as shown. Upper plate 60 includesa cavity 66 formed in its lower surface to receive lens 24 and definesthe upper surface of a mold cavity 72 for gasket 28. It should beunderstood that cavity 66 may be configured to accept any desired curvedor shaped lens and may accommodate a wide range of gasket dimensions andthicknesses. In the embodiment shown, lower plate 62 includes a supportsurface 68 for lens 24 and the lower surface of mold cavity 72, which,together with cavity 66, defines a lens cavity 70 and the mold cavity72. Mold cavity 72 is in fluid communication with a runner system 74,which in turn is in fluid communication with a nozzle (not shown) of aconventional plastic injection machine. Preferably, runner system 74 iscentrally located and configured within lower plate 62 to direct thegasket material to mold cavity 72 through at least two gates (notshown), which are positioned on opposed ends of lens cavity 70 on theparting line 63 of lower plate 62. In this manner, the gasket materialis injected uniformly into cavity 72. It should be understood that thenumber of gates can be increased as needed to increase the flow ofgasket material to cavity 72 and to assure a more uniform flow.

Additionally, the lower and upper plates 60, 62, respectively, have beenconfigured to form a mold cavity that forms a three-sided encapsulationabout peripheral edge 30 of lens 24. As it should be understood from thedescription of lens module 23, mold cavity 72 may be configured forencapsulating one or two sides of lens 24 or for forming a molded memberon an intermediate portion of a polymeric element or for forming amolded member with an attachment member encapsulated in the moldedmember.

In the illustrated embodiment, mold apparatus 58 is a vertical moldapparatus. The vertical configuration of mold apparatus 58 has theadvantage that lens module 23 is gravity-supported on plate 62, whichresults in ease of loading and alignment without need for vacuum assistsand the like. However, it should be understood that a horizontal moldapparatus may also be used.

The opening and closing of mold apparatus 58 is achieved usingconventional methods. For example, upper plate 60 may be mounted on athird fixed plate and can be guided by guide pins, hydraulic cylinders,or the like (not shown). Alternatively, a hinge mechanism (not shown)can also be used with the upper or lower plate 60, 62. When at the fullyopen mold position, lens 24 may be placed on the support surface oflower plate 62. After loading the lens into mold apparatus 58, and afterthe mold is closed as shown in FIG. 1, the melt-processible gasketingmaterial is injected into the mold cavity 72. Upon filling of the moldand substantial completion of any set up, cure, and/or cross-linkingreactions in the gasketing material, the mold is opened. The lens module23 can then be removed from mold apparatus 58 which is then ready foranother lens in a new cycle.

Although the present invention is described in reference to a headlampassembly and to a decorative panel assembly, it should be understoodthat the present invention may be used in numerous other applications,including other vehicle component assemblies incorporating protectivecoated polymeric elements, especially protective coated polycarbonateelements. Other vehicle component assemblies include: window assembliesincorporating a polymeric window element or panel, trim assembliesincorporating protective coated polymeric elements, reflective elementassemblies, and other lighting assemblies, for example tail lights andinterior lighting assemblies. Furthermore, as described previously,module 23 may be formed using several processes. Optionally, lens module23 is formed using a pre-formed, pre-coated lens which is primed, asdescribed above, and then placed in an injection molding apparatus whichintegrally molds molded member 28 onto the primed, pre-formed,pre-coated lens. However, lens module 23 may also be formed by using apre-formed uncoated lens which is then subsequently coated with aprotective coating using any one of the conventional techniquesdescribed previously. After coating, the coated lens is then primed andmolded with molded member 28 as described above to form lens module 23.Alternatively, lens 24, coatings 27 a-27 d, and molded member 28 may beformed in a single mold such as, co-injection machine or molded instages in adjacent injection/co-injection molding machines.Alternatively, the molded member 28 may be formed around the perimeterof the coated lens using an extrusion process that extrudes the polymermaterial that forms the molded member 28 from a shaped extrusion head.The shaped extrusion head extrudes the desired shape profile of thepolymer material, including the gap closing flange and lip, and movesaround the perimeter of the lens such as by mounting on a robot arm.

While several forms of the invention have been shown and described,other forms will now be apparent to those skilled in the art. Therefore,it will be understood that the embodiment shown in the drawings anddescribed above are merely for illustrative purposes and not intended tolimit the scope of the invention which is defined by the claims whichfollow.

What is claimed is:
 1. A vehicular lighting assembly suitable for use ina vehicle, said vehicular lighting assembly comprising: a light source;a polymeric element including a protective coating on at least a portionof said polymeric element, said light source projecting light throughsaid polymeric element when said light source is powered by a powersource; and a polymeric molded member integrally molded on and bondingto at least a portion of said protective coating.
 2. The lightingassembly according to claim 1, further comprising an attachment memberextending from said polymeric molded member.
 3. The lighting assemblyaccording to claim 2, wherein said polymeric element includes saidattachment member.
 4. The lighting assembly according to claim 2,wherein said attachment member is at least partially molded with saidpolymeric molded member.
 5. The lighting assembly according to claim 2,wherein said attachment member comprises a fastener.
 6. The lightingassembly according to claim 1, wherein said polymeric element comprisesa polycarbonate element.
 7. The lighting assembly according to claim 6,wherein said polycarbonate element includes a primer coating on at leasta portion of said protective coating, said polymeric molded member beingintegrally molded with said polymeric element on at least a portion ofsaid primer coating.
 8. The lighting assembly according to claim 1,further comprising an ultraviolet radiation absorber/stabilizer forprotecting said polymeric element from ultraviolet radiationdegradation.
 9. The lighting assembly according to claim 8, wherein saidprotective coating comprises said ultraviolet radiationabsorber/stabilizer.
 10. The lighting assembly according to claim 1,wherein said polymeric molded member comprises a non-melt processiblegasket material.
 11. The lighting assembly according to claim 1, whereinsaid polymeric molded member comprises a melt processible gasketmaterial.
 12. The lighting assembly according to claim 1, wherein saidpolymeric molded member comprises a gasket material, said gasketmaterial comprising at least one material chosen from a polyvinylchloride, a styrene/butadiene/styrene elastomer, astyrene/ethylene/butadiene/styrene elastomer, a copolyester elastomer, apolyether blockamide, a thermoplastic urethane, a styrene butadienerubber elastomer, an ethylene propylene diene terpolymer elastomer, andan ethylene propylene copolymer elastomer.
 13. The lighting assemblyaccording to claim 1, wherein said protective coating comprises onechosen from an organic coating, an inorganic coating, and anorganic/inorganic coating.
 14. The lighting assembly according to claim13, wherein said protective coating comprises at least one of an oxideof silicon and an oxide of titanium.
 15. The lighting assembly accordingto claim 1, wherein said polymeric element includes a contoured surface.16. The lighting assembly according to claim 15, wherein said contouredsurface follows a contour of the vehicle.
 17. The lighting assemblyaccording to claim 1, wherein said polymeric element is adapted toprovide an optical property.
 18. A lamp module suitable for use in avehicle, the vehicle having a body and an opening in the body, said lampmodule comprising: a polymeric light transmitting element having aprotective coating on at least a portion of said polymeric element; anda polymeric member integrally molded on and bonding to at least aportion of said protective coating.
 19. The lamp module according toclaim 18, wherein said polymeric member comprises a portion adapted tocover a gap between said polymeric light transmitting element and theopening in the body of the vehicle.
 20. The lamp module according toclaim 18, wherein said polymeric light transmitting element comprises apolycarbonate element.
 21. The lamp module according to claim 20,wherein said polycarbonate element is adapted to provide an opticalproperty.
 22. The lamp module according to claim 18, wherein saidpolymeric light transmitting element includes an inner side surfacehaving said protective coating on at least a portion thereof, saidpolymeric member being injection molded on said protective coating onsaid portion of said inner side surface.
 23. The lamp module accordingto claim 18, wherein said polymeric light transmitting element includesan inner side surface at a peripheral portion of said polymeric lighttransmitting element and an edge surface at said peripheral portion;said polymeric member being injection molded on a portion of saidprotective coating on at least said inner side surface and said edgesurface of said polymeric light transmitting element.
 24. The lampmodule according to claim 18, wherein said polymeric light transmittingelement includes a contoured surface.
 25. The lamp module according toclaim 24, wherein said contoured surface follows the contour of the bodyof the vehicle.
 26. The lamp module according to claim 24, wherein saidpolymeric light transmitting element comprises a lens.
 27. The lampmodule according to claim 18, wherein said polymeric light transmittingelement further includes a primer coating, said primer coating being onat least a portion of said protective coating.
 28. The lamp moduleaccording to claim 27, wherein said polymeric member is integrallymolded on and bonded to at least a portion of said primer coating. 29.The lamp module according to claim 18, wherein said polymeric membercomprises a non-melt processible gasket material.
 30. The lamp moduleaccording to claim 18, further comprising a primer coating disposedbetween said protective coating and said polymeric member.
 31. The lampmodule according to claim 18, wherein said polymeric member comprises amelt processible gasket material.
 32. The lamp module according to claim18, wherein said polymeric member comprise a gasket material, saidgasket material comprising at least one material chosen from a polyvinylchloride, a styrene/butadiene/styrene elastomer, astyrene/ethylene/butadiene/styrene elastomer, a copolyester elastomer, apolyether blockamide, a thermoplastic urethane, a styrene butadienerubber elastomer, an ethylene propylene diene terpolymer elastomer, andan ethylene propylene copolymer elastomer.
 33. The lamp module accordingto claim 18, wherein said protective coating comprises one chosen froman organic coating, an inorganic coating, and an organic/inorganiccoating.
 34. The lamp module according to claim 32, where saidprotective coating comprises at least one of an oxide of silicon and anoxide of titanium.
 35. The lamp module according to claim 18, wherein atleast one of said polymeric light transmitting element and saidprotective coating includes an ultra violet radiationabsorber/stabilizer.